ATC INNOVATIVE MOBILITY ATC TRUCK OWNER S MANUAL CHEVROLET SILVERADO / GMC SIERRA ATC Manufacturing 4654 East Markle Road Markle, IN 46770 service@atconversions.com www.atconversions.com ATC provides a life-changing experience through mobility with style! Ver: 06/23/17
TABLE OF CONTENTS CONTENTS PAGE TABLE OF CONTENTS...2 WARNINGS Vehicle Setup... 3 WARNINGS Chair Adjustments... 4 Inspecting Your Lift After A Crash... 4 choosing a parking location... 4 alternative uses... 4 towing with your atc vehicle... 4 repairs covered... 4 MAINTENANCE Damage Due To Insufficient Or Improper Maintenance... 5 Maintenance... 5 FACTORY SEAT Installing Factory Seat... 6 Removing Factory Seat... 6 CONTROL PANEL/CIRCUIT BREAKERS Control Panel Layout... 7 Control Panel... 8 Circuit Breakers... 8 LIMIT SWITCH Limit Switch Function... 9 KEY FOB Key FOB Buttons... 11 MANUAL OPERATION Manual Hydraulic Pump Operation... 12 WARRANTY ATC MANUFACTURING, LLC LIMITED WARRANTY...14 2 www.atconversions.com Technical Service: (877) 291-6309 service@atconversions.com
WARNINGS LIFT SPECIFICATIONS DOT Private Use lift Operator must back into lift Lift rating: 750 Pounds Minimum unobstructed platform operating volume: 57,000 cubic inches. Operating the Lift To ensure that the lift is operated in a safe manner, the following precautions should be understood and followed. VEHICLE SETUP To increase safety, your vehicle and wheelchair should be configured for safe driving by a professional. This includes required controls and wheelchair configuration on the lifting platform. Seat belt modification or extension may be required depending on the size of the wheelchair and individual application which should also be configured by a professional. NOTE: An aftermarket seatbelt and/or extension must not be used unless it latches into the OEM receptacle. When this OEM receptacle is latched, it is a safety feature which will not allow the door to open. If the door opens with the seatbelt positioned in any other way, it could possibly cause injury to the occupant or damage to the vehicle. The wheelchair must be locked in place by an E-Z Lock or equivalent system to ensure it cannot be moved during operation of the vehicle. Locking mechanism is operator and wheelchair specific so must be installed by a qualified local dealer to ensure proper operation. Careful observation of the lift must be followed while operating. Keep all objects away from the door while opening and closing. Take great care to observe door opening/closing and lift movement through its complete cycle. To stop the sequence, simply release the remote button. Door must be fully open before lift tray is deployed. The lift mechanism and door linkages have pinch points. Please keep all people, objects and body parts away from the mechanisms while in operation. The lift mechanism involves a number of moving parts that are capable of generating a large amount of force. Do not store objects in the vicinity of the mechanism, or where they could be dislodged into the lift where they could be crushed or damaged. Do not attempt to service the lift mechanism. Service should only be complete by a trained professional from your authorized All-Terrain Conversions (ATC) dealer. www.atconversions.com Technical Service: (877) 291-6309 service@atconversions.com 3
WARNINGS Avoid all wires and electrical components of the vehicle. These components must be serviced by your local authorized ATC Dealer. With head restraints that are not installed and adjusted properly, there is a greater chance that occupants will suffer a neck/spinal injury in a crash. Do not drive until the head restraints for all occupants are installed and adjusted properly, including the wheelchair. CHAIR ADJUSTMENTS! WARNING You can lose control of the vehicle if you try to adjust the wheelchair while the vehicle is moving. The sudden movement could startle and confuse you, or cause unexpected manipulation of the vehicle controls. Make all adjustments only when the vehicle is not moving and disable the controls on a power chair if possible. INSPECTING YOUR LIFT AFTER A CRASH! WARNING A crash can damage the lift mechanism or various other components of the system causing it to operate in a manner different than intended, resulting in premature wear, serious injury or even death. To insure that your lift is working optimally, have it inspected and any necessary replacements made as soon as possible. CHOOSING A PARKING LOCATION! WARNING Do not operate your lift in an area that is not flat and level. Unlevel ground could cause the platform to not sit evenly on the ground and could cause the chair to tip or bounce when entering or leaving the lift. ALTERNATIVE USES! WARNING Using this lift for uses other than what it is intended for can be dangerous and result in injury or death. Not only can this be dangerous, but it will also void the warranty. Examples of non-approved uses include cargo loading or attempting to use the lift to raise the vehicle. TOWING WITH YOUR ATC VEHICLE! WARNING Do not attempt to tow with the vehicle bumper due to the body lift installation. All towing should be done with a class III receiver type hitch only. REPAIRS COVERED 4 The warranty covers repairs to correct any conversion defect related to materials or workmanship occurring during the warranty period. Needed repairs will be performed using new or remanufactured parts. Damage caused by failure to follow specified guidelines within this manual will not be covered under warranty. www.atconversions.com Technical Service: (877) 291-6309 service@atconversions.com
MAINTENANCE DAMAGE DUE TO INSUFFICIENT OR IMPROPER MAINTENANCE Damage caused by failure to follow the recommended maintenance schedule intervals and/or failure to use or maintain fluids, fuel, lubricants, or refrigerants recommended in the OEM owner s manual is not covered. MAINTENANCE ATC recommends biannual service inspections from your local authorized dealer. Replacement parts should only be installed by your local dealer. Visual inspections should be performed on a regular monthly basis by the operator. ATC conversion requires separate inspection from normal vehicle maintenance. Both vehicle and conversion inspection should be done per recommended schedules. Minimum inspection should include the following components. Inspection should include visual check for wear or damage on all linkages and lift components, operational check for any unusual sounds or erratic operation, hydraulic fluid levels, hydraulic hoses and covers and electrical wiring. All maintenance must be performed by trained professionals from your local authorized All-Terrain Conversions Dealer. INSPECTION ITEM INSPECTION CRITERIA INSPECTION FREQUENCY Bushing on all hinge points Bearing on slide and lift Mechanical linkages and lift beams Electrical wiring Hydraulic cylinders, pump, and manifold Hydraulic hoses and abrasive jacket Truck undercarriage Tire damage, wear and pressure Clean and check for any wear, out of round bushing ID, rust, unusual noise or motion Check for any wear, out of round bushing ID, rust, unusual noise or motion Check for any signs of mechanical damage, missing components, excessive rust or loose fasteners. Corrosion at connection points, wear or chafing of insulation, pinched or cut wires. Routing to avoid any potential damage. Check for proper fluid level in tank (DO NOT TOP OFF WITH CYLINDERS EXTENDED, MAY CAUSE OVERFLOW), leaks, damage, abrasion or abnormal wear. Any abrasion, wear or damage. Routing to avoid any potential damage. Damage and excessive rust, reapply Rust prevention as necessary Check for any signs of damage, uneven wear, and proper inflation Monthly by operator and biannually by local authorized dealer. Monthly by operator and biannually by local authorized dealer. Monthly by operator and biannually by local authorized dealer. Monthly by operator and biannually by local authorized dealer. Monthly by operator and biannually by local authorized dealer. Monthly by operator and biannually by local authorized dealer. Biannually by local authorized dealer. Monthly by operator. www.atconversions.com Technical Service: (877) 291-6309 service@atconversions.com 5
FACTORY SEAT INSTALLING FACTORY SEAT To install the original factory seat, position the seat onto the lift platform and align the latches with the latch pins. Move the seat rearward until the latches engage the pins. Connect the seat plug if so equipped. WARNING When installing the original vehicle seat, insure that the seat base is correctly installed to the lift platform and that the locking latches are engaged. Failure to do this will allow the seat to move unexpectedly and possibly causing you to lose control of the vehicle. An unsecured seat will increase the likelihood of injury in a crash. REMOVING FACTORY SEAT Disconnect the seat plug if so equipped. Pull the cable release to release the latches. Move the seat to clear latch pins and remove seat. 6 www.atconversions.com Technical Service: (877) 291-6309 service@atconversions.com
CONTROL PANEL/CIRCUIT BREAKERS CONTROL PANEL LAYOUT Wire drops are located under the left side of dash for lockdown mechanism switches and at lift pan for lockdown mechanism. Wires are pre-run for a wheelchair docking mechanism which are located under driver side dash and run under carpet to the lift pan. Under Driver Side Dash to Lift Pan: 16g Red w/white stripe, 16g Black, 18g White, 18g Green w/white stripe, 18g Red, 18g Black This wiring configuration must be maintained. 1. 12 Volts (+) from 16 amp breaker 2. 12 Volts (+) from 16 amp breaker 3. 12 Volts (+) from 16 amp breaker 4. 12 Volts (+) from 16 amp breaker 5. 12 Volts (+) from 16 amp breaker 6. Ground (-) 7. Ground (-) 8. Open 9. Open www.atconversions.com Technical Service: (877) 291-6309 service@atconversions.com 7
CONTROL PANEL/CIRCUIT BREAKERS CONTROL PANEL The Control panel is located behind the rear seat toward the bottom and can be accessed for monitoring by lifting the lower portion of the seat. For repair or replacement of the control panel, the rear seat will need to be removed. LED lighting matches the indication label to identify what state the lift and door operation is in. Push the push button breaker IN to turn the ATC Control Boards ON, depress to turn OFF. Control Boards utilize a sleep mode after non-use to save on battery draw even though it is minimal. CIRCUIT BREAKERS Located in the engine compartment near the OEM battery is a 250 AMP Mega Fuse protecting the hydraulic system motor along with a 20 AMP Auto Reset circuit breaker for both control boards. This wiring configuration must be maintained on OEM battery if an auxiliary battery is installed. A push button breaker that protects the control circuitry and the boards themselves is located on the control board assembly. 8 www.atconversions.com Technical Service: (877) 291-6309 service@atconversions.com
LIMIT SWITCH LIMIT SWITCH FUNCTION Limit Switch s Purpose Senses when the door is closed and the lift is either in or out and also up so the next function can be started. Location There are 4 limit switches controlling the hydraulic actuation of the door & lift system. Each limit switch senses a corresponding magnet to signal end of stroke. The Door Close sensor is located in the center of the vertical support plate with a magnet mounted on the door standoff. The tray out sensor is mounted on the lift s pivot. The tray in sensor is mounted at the back of the floor pan. Sensing magnets are mounted opposite these sensors. The fourth sensor is mounted on the lift upright to sense when the lift pan is in the full up position. The magnet is mounted on the back of the lift pan. Adjustment Limit switch sensing distance should be adjusted by turning the jam nuts on either side of limit switch. Ensure there is no interference with motion of the tray and magnet, and the limit switch is within ½ inch of the magnet to ensure proper signal to the controller. Jam nuts to position & lock sensors. Tray Out sensor on pivot pin. Door Close sensor in vertical support plate of pivot. www.atconversions.com Technical Service: (877) 291-6309 service@atconversions.com 9
Tray In sensor on truck side and magnet on pivot arm. Door Close sensor in vertical support plate of pivot. A Tilt Switch is located on the link which opens the door. This switch will limit the outward movement of the lifting platform until the door is up and out of the way as indicated to the control system by this switch. 10 www.atconversions.com Technical Service: (877) 291-6309 service@atconversions.com
KEY FOB KEY FOB BUTTONS ALWAYS START VEHICLE PRIOR TO OPENING OR CLOSING DOOR AND RAMP. Key Fob Button Description 1. Press and hold OPEN for the gullwing door to Open. 2. Press and hold CLOSE for the gullwing door to Close. 3. Press and hold for the lift to go Up and In. 4. Press and hold for the lift to go Out and Down. 1 2 3 4 An aftermarket Alarm/Remote Start system may have been installed to interface with the TouchTronics control modules if the truck was not originally equipped with a remote start system. The aftermarket FOBs may be used but are not needed. SAFETY Lift tray must not be deployed until door is fully opened. Damage may result if the lift tray makes contact with the door. SAFETY *Safety: Door will not function with the converted side s seat belt latched. SAFETY *Safety: Door will not function with the truck running and foot on brake. www.atconversions.com Technical Service: (877) 291-6309 service@atconversions.com 11
MANUAL OPERATION MANUAL HYDRAULIC PUMP OPERATION Hydraulic hand pump can be used to operate any of the hydraulic circuits in case of emergency or loss of battery power. Manual operation should not be used for daily operation of the hydraulic system. In a situation where manual operation of the hydraulic system is necessary, first ensure electrical power to the system has been shut off, and all electrical controls are off. To operate pump: 1. Ensure there is adequate hydraulic oil in the reservoir tank. 2. Ensure there are no objects or persons in the way of operating the ramp. 3. Insert handle for hand pump into pump handle receptacle. Location P on picture below. 4. Operate pump and ensure the pump is building pressure (resistance to pumping) before operating any of the manual valves. It may take additional strokes of the hand pump to fully prime the system if it has not been used recently. 5. Select which hydraulic cylinder or operation you wish to move and select appropriate valve to operate (A, B, or C). Do not operate more than one valve at a time. PIN Pull Red Pin to Acuate* A1 Door Open A2 Tray / Chair Up A3 Horizontal Tray Out B1 Door Close B2 B3 Tray / Chair Down Horizontal Tray In A1 B1 * Make sure to move Pin counterclockwise back to the original position before operation. A2 A3 B2 B3 6. Pull the appropriate red Pin while simultaneously operating the hand pump to move the cylinders while verifying safe motion of the ramp. The red Pin may be pulled out and turned clockwise to lock position so it does not have to be held while pumping. 12 www.atconversions.com Technical Service: (877) 291-6309 service@atconversions.com
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WARRANTY ATC MANUFACTURING, LLC LIMITED WARRANTY ATC MANUFACTURING, LLC warrants to the original consumer that its products shall be free from defects in materials and workmanship for a period of three (3) years or 36,000 miles, whichever comes first At its option, ATC will repair or replace at no charge any ATC product that proves to be defective within such warranty period. This warranty shall not apply if the ATC product has been damaged by unreasonable use, accident, negligence, service or modification by anyone other than ATC or its affiliates, or by any other causes unrelated to materials and workmanship. Exclusions and Additional Limitations This warranty relates to the condition of ATC MANUFACTURING at the time it is manufactured and does not cover parts or service as a result of: a) Any expense not pre approved, in writing by ATC Manufacturing. Consideration will be given for emergency expenses when ATC Manufacturing can not be reached by calling Service Department at (877) 291-6309. b) Normal wear and tear or required maintenance c) Abuse including, without limitation: neglect, improper operation, misapplication, overloading, accident or alterations not approved by ATC MANUFACTURING. d) Lack of maintenance including, without limitation: failure to inspect and maintain, improper repair, use of parts not approved by ATC. All parts must be obtained from or approved by ATC MANUFACTURING. e) Damage caused in transit or as the result of the following: i. Acts of God, collision, fire, theft, freezing, vandalism, riot, explosion, or objects striking the vehicle ii. Misuse of the vehicle such as overloading, racing or other offroad competition. iii. Damage caused by failure to follow the recommended maintenance schedule intervals and/or failure to use or maintain fluids, fuel, lubricants, or refrigerants recommended in the vehicles owner s manual. f) Customer modifications including but not limited to software changes, mechanical alterations or changes in the vehicle s center of gravity. g) Surface rust and paint peeling are NOT covered by warranty, however it is recommended that rust should be sanded and repainted to maintain structural integrity as a part of routine maintenance. Structural failure due to rust will be deemed as improper maintenance and not covered by warranty h) Rental vehicles are not a covered expense while vehicle is being repaired or serviced. ATC MANUFACTURING will not be liable for any consequential damages, loss or expense arising in connection with the use of or the inability to use its goods for any purpose whatsoever. ATC MANUFACTURING S maximum liability shall not in any case exceed the contract price for the goods claimed to be defective or unsuitable. Products will be considered accepted by customer unless written notice to the contrary is given to ATC within ten (10) days of such delivery to customer. ATC shall not in any case be liable for any event occurring or defect discovered with regard to said product unless written notice thereof is given to ATC within thrity (30) days of such product delivery to customer. ATC is not responsible for loss or damage to products owned by customer and located on ATC MANUFACTURING S premises caused by fire or other casualties beyond ATC S control. ATC Dealers may offer services on credit accepting payment directly from ATC Manufacturing. However, in the event a dealer or service provider does not extend credit, pre approved services will have to be paid for by customer and submitted directly to ATC Manufacturing for reimbursement. Approved expenses will be reimbursed by check and mailed within 30 days of receiving all materials deemed necessary by ATC Manufacturing. 14 www.atconversions.com Technical Service: (877) 291-6309 service@atconversions.com
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